SD-31-70082 Service Bulletin/Repair Instructions

SD-31-70082

Bendix® iSense™ and iSense™ Pro Air Disc Brake (ADB)

Electronic Control Unit (ECU) for TRACTORS

This document covers the iSense and

iSense Pro ECU for TRACTORS*
Bendix wear-sensing ECUs are designed to be

warning-only devices. The information broadcast by

the ECU should not be used to make adjustments to

the braking characteristics of the vehicle.
*Refer to SD-31-7570 on B2Bendix.com for information related to the

iSense Pro ECUs for trailer.
INTRODUCTION

The Bendix® iSense™ and iSense™ Pro Air Disc Brake

(ADB) Wear-Sensing Tractor Electronic Control Unit (ECU)

is a device designed to help improve the brake pad and

rotor life-monitoring ability of vehicles equipped with Bendix

tractor ADBs. The ECU makes use of the following types

of Bendix wear sensors:

•
iSense Wear Sensor: signals when the pad thickness

approaches replacement condition for each wheel-end
•
iSense Pro Wear Sensor: actively monitors the

percentage of remaining brake life versus replacement

condition at each wheel end as a combined

measurement of the inboard pad, outboard pad, and

rotor
The ECU can monitor either the iSense or iSense Pro wear

sensor on up to eight (8) wheel-ends on a single vehicle.
The driver is always responsible for the control and

safe operation of the vehicle at all times. The Bendix

wear-sensing ECU does not replace the need for a

skilled, alert, professional driver, performing pre-trip

inspections, reacting appropriately and in a timely

manner, and using safe driving practices. Wear-sensing

ECUs do not substitute the need to perform regular

inspections and perform preventative maintenance.
IMPORTANT

Wear sensing does not replace the need for routine

inspections. Routine inspections should always be

conducted. Refer to SD-23-7541, Bendix® ADB22X®,

ADB22X-V ™ and ADB22X ®-LT Air Disc Brakes, on

B2Bendix.com for further inspection details.
HARDWARE CONFIGURATION

The ADB wear-sensing ECU is designed to work on a 12V

system and is compatible with 250k and 500k baud rate

J1939 CAN buses.
Figure 1 – ADB Wear-Sensing ECU
1
GENERAL SAFETY GUIDELINES
WARNING! PLEASE READ AND FOLLOW THESE INSTRUCTIONS

TO AVOID PERSONAL INJURY OR DEATH:
When working on or around a vehicle, the following guidelines should be observed AT ALL TIMES:

▲ Park the vehicle on a level surface, apply the ▲ Never connect or disconnect a hose or line

parking brakes, and always block the wheels.

containing pressure; it may whip and/or cause

Always wear personal protection equipment.

hazardous airborne dust and dirt particles. Wear

eye protection. Slowly open connections with

▲ Stop the engine and remove the ignition key

care, and verify that no pressure is present. Never

when working under or around the vehicle.

remove a component or plug unless you are

When working in the engine compartment,

certain all system pressure has been depleted.

the engine should be shut oﬀ and the ignition

key should be removed. Where circumstances ▲ Use only genuine Bendix ® brand replacement

require that the engine be in operation, EXTREME

parts, components, and kits. Replacement

CAUTION should be used to prevent personal

hardware, tubing, hose, fittings, wiring, etc.

injury resulting from contact with moving,

must be of equivalent size, type, and strength as

rotating, leaking, heated, or electrically charged

original equipment and be designed specifically

components.

for such applications and systems.

▲ Do not attempt to install, remove, disassemble, ▲ Components with stripped threads or damaged

or assemble a component until you have read,

parts should be replaced rather than repaired.

and thoroughly understand, the recommended

Do not attempt repairs requiring machining or

procedures. Use only the proper tools and

welding unless specifically stated and approved

observe all precautions pertaining to use of those

by the vehicle and component manufacturer.

tools.

▲ Prior to returning the vehicle to service, make

▲ If the work is being performed on the vehicle’s

certain all components and systems are restored

air brake system, or any auxiliary pressurized air

to their proper operating condition.

systems, make certain to drain the air pressure ▲ For vehicles with Automatic Traction Control

from all reservoirs before beginning ANY work

(ATC), the ATC function must be disabled (ATC

on the vehicle. If the vehicle is equipped with

indicator lamp should be ON) prior to performing

®

®

®

a Bendix AD-IS air dryer system, a Bendix

any vehicle maintenance where one or more

DRM™ dryer reservoir module, a Bendix® AD-9si®,

wheels on a drive axle are lifted oﬀ the ground

AD-HF®, or AD-HFi® air dryer, be sure to drain the

and moving.

purge reservoir.

▲ The power MUST be temporarily disconnected

▲ F o l l o w i n g t h e v e h i c l e m a n u f a c t u r e r ’s

from the radar sensor whenever any tests USING

recommended procedures, deactivate the

A DYNAMOMETER are conducted on a vehicle

electrical system in a manner that safely removes

equipped with a Bendix® Wingman® system.

all electrical power from the vehicle.

▲ Never exceed manufacturer’s recommended

pressures.

▲ You should consult the vehicle manufacturer's operating and service manuals, and any related literature,

in conjunction with the Guidelines above.
2
ECU MOUNTING
SAE J1939 SERIAL COMMUNICATIONS
Bendix Air Disc Brake (ADB) wear-sensing Electronic

Control Units (ECUs) can be mounted within the cab

or mounted on the rear of the chassis away from any

heat sources and is compatible with either iSense or

iSense Pro wear sensors. The ECU connector should

be installed only by hand until it clicks into place. The

ECU has two (2) through-hole mounting tabs to be used

for mounting. Refer to Original Equipment Manufacturer

(OEM) documentation regarding mounting methods and

torques.
A Controller Area Network (CAN) data link (SAE J1939) is

provided for communication. This link is used for various

functions, including broadcasting the brake pad and rotor

life remaining and circuit diagnostic messages.
®
To ensure the product performs as intended and to prevent

corrosion, all unused pin locations in the ECU connectors

must be plugged and receive any necessary protection

from moisture, etc. The ADB wear-sensing ECU utilizes a

connector from the Deutsch® DT product family.
SOFTWARE CONFIGURATION

Bendix ADB wear-sensing ECUs are not re-configurable

and are sold with a pre-configured software set that is

identified by a part number. Refer to B2Bendix.com for the

correct part number.
ELECTRONIC CONTROL UNIT (ECU) INPUTS

AND OUTPUTS

The ADB wear-sensing ECU has one (1) ignition power

and one (1) ground input and is designed to operate at a

nominal supply voltage of 12V. The ignition power input

is the power source for the ECU and should be supplied

through a 5-amp fuse. The operating voltage range is 9.0V

to 18.0V.
IMPORTANT

ECU operation is not guaranteed outside of the

operating range.
ECU WIRING HARNESS

Bendix does not provide the wiring harness that connects

to the ECU. It is the responsibility of the OEM to incorporate

the wear-sensing ECU wiring harness into their vehicle

harness. The minimum wire gauge for connectors is

20 AWG. The ECU connector should be secured by

hand until the connector clicks into place. Refer to the

Troubleshooting: Electronic Control Unit (ECU) Wiring

Harness Connectors section of this document.
The wear-sensing ECU utilizes SAE J1939 CAN protocol

to communicate brake pad and rotor wear status. The

ECU utilizes PGN 65196 - Wheel Brake Lining Information

message to broadcast brake pad and rotor wear information.
DIAGNOSTIC TROUBLE CODES (DTCs)

FOR ISENSE PRO SENSORS

If an issue is detected with one of the iSense Pro wear

sensors, a DTC will be broadcast to indicate what kind

of failure that sensor is experiencing. All other wear

sensors should maintain normal function. Refer to the

Troubleshooting section for more information.
ISENSE WEAR SENSOR

iSense wear sensors are clipped onto the inboard and

outboard pad of the wheel end. The sensor is a wearable

component that is to be replaced with each pad change.
ISENSE PRO WEAR SENSOR

iSense Pro wear sensors provide a combined measurement

(as a percentage) of the inboard and outboard brake pads

plus the remaining rotor thickness on each wheel-end ADB.

The sensor is incorporated into the ADB for wear sensing

from the factory. The calibrated wear sensor provides a

voltage output to the ECU. This signal is then converted to

a percentage and broadcast over the J1939 CAN bus. The

iSense Pro wear sensor functions on a 5V supply voltage.

If the sensor outputs a voltage signal of less than 4V, the

brake wear life remaining is in the “good” range. If the

sensor outputs a voltage signal of greater than or equal to

4V, the brake wear life remaining is considered to be “worn.”
IMPORTANT

Use of this sensor does not substitute the need for

routine inspection and maintenance.

NOTE: Request of ADB wear sensing must be specified

at the time of order, as iSense Pro wear sensors cannot

be installed after the caliper has already been assembled.
SENSOR POWER AND GROUND

The ECU supplies three (3) 5V power and ground outputs to

be utilized by the iSense Pro wear sensor. Refer to Table 2.
3
PGN
65196
65216
PARAMETER

GROUP

LABEL
Wheel

Brake Lining

Remaining

Information
Service

Information
ACRONYM
EBC4
SERV
SPN
SPN LABEL
DATA RANGE
ECU AXLE

CONFIGURATION

2

AXLE
3

AXLE
4

AXLE
1099
Front Axle, Left Wheel
2% (iSense) or 100%

iSense Pro: 0% to 100%
X
X
X
1100
Front Axle, Right Wheel
2% (iSense) or 100%

iSense Pro: 0% to 100%
X
X
X
1101
Rear Axle #1, Left Wheel
2% (iSense) or 100%

iSense Pro: 0% to 100%
X
X
X
1102
Rear Axle #1, Right Wheel
2% (iSense) or 100%

iSense Pro: 0% to 100%
X
X
X
1103
Rear Axle #2, Left Wheel
2% (iSense) or 100%

iSense Pro: 0% to 100%
X
X
1104
Rear Axle #2, Right Wheel
2% (iSense) or 100%

iSense Pro: 0% to 100%
X
X
1105
Rear Axle #3, Left Wheel
2% (iSense) or 100%

iSense Pro: 0% to 100%
X
1106
Rear Axle #3, Right Wheel
2% (iSense) or 100%

iSense Pro: 0% to 100%
X
911
Service Component Identification
Not Broadcast (or 15)
X
X
X
Table 1 – Communication
COMMUNICATION
DRIVER WARNING DEVICES
The ADB wear-sensing ECU can utilize all eight (8) SPNs

of PGN 65196 correlating to the front axle, rear axle #1,

rear axle #2, and rear axle #3 depending on the ECU axle

configuration. Refer to Table 1.
Individual OEMs are responsible for integrating this

information into their dash. OEMs shall follow those rules

laid out in Federal Motor Vehicle Safety Standards (FMVSS)

for warning light operation, symbol, and color for brake pad

and rotor wear.
Refer to Table 5 for further information on SPN/FMI.
IMPORTANT

The ADB wear-sensing ECU may broadcast the “Service

Component Identification” message with the number

“15” if any wheel position is below 10% life remaining

or there is a Diagnostic Trouble Code (DTC) present.

That message will not stop broadcasting until all wheel

positions are above 15% life remaining and there are

no DTCs active.
4
TROUBLESHOOTING

ECU DIAGNOSTICS
USING PC-BASED DIAGNOSTICS
The ADB wear-sensing ECU contains self‑testing diagnostic

circuitry that continuously checks for the normal operation of

external wear-sensing components and wiring. Diagnostics

are only available on units configured for iSense Pro wear

sensors. DTCs only pertain to iSense Pro applications.

iSense applications will not broadcast DTCs.
ACom Diagnostic Software is an RP-1210-compliant

PC-based diagnostic software program. With ACom

Diagnostic Software, maintenance personnel can:

•
 btain Diagnostic Trouble Code (DTC) information

O

(both active and inactive DTCs)
•
Retrieve event history
ACTIVE DTCs
•
Clear inactive DTCs and event history
When a DTC is detected, the ADB wear-sensing ECU

performs the following:
•
Verify Electronic Control Unit (ECU) configuration
•
Perform system and component tests
•
Read/write customer information in the scratch pad
2. The ECU communicates the appropriate DTC

information over the serial communication diagnostic

link as required.
•
Save and print information
•
Receive troubleshooting assistance
ACTIVE DTC MODE
When using ACom Diagnostic Software to diagnose the

Air Disc Brake (ADB) wear-sensing ECU, the computer’s

serial, parallel, or USB port needs to be connected to

the vehicle’s diagnostic connector. For more information

and to download ACom Diagnostic Software, visit

B2Bendix.com.
1. The ECU places the appropriate DTC information in

the ECU memory.
All active DTCs may be retrieved using a hand‑held

or PC‑based diagnostic tool, such as Bendix ® ACom®

Diagnostic Software.
INACTIVE DTC MODE
PC-based diagnostic tools attach to the vehicle diagnostic

connector. See Figure 2.
The ADB wear-sensing ECU stores past DTCs in its

memory. The record is commonly referred to as “event

history.” When an active DTC is cleared, the ECU stores

it in the event history memory as an inactive DTC. Inactive

DTCs and event history may be retrieved and cleared

by using a PC-based diagnostic tool, such as ACom

Diagnostic Software.
Figure 2 – Typical Vehicle Diagnostic Connector
5
WIRING HARNESS CONNECTOR PIN

ASSIGNMENTS
TECHNICAL ASSISTANCE
The ECU utilizes one (1) Deutsch connector for wire

harness connections. See Figure 3 and refer to Table 2.
For additional assistance, the Bendix Tech Team can be

reached by email at techteam@bendix.com or by phone

at 1-800-AIR-BRAKE (1-800-247-2725), option 2. Bendix

Tech Team representatives are available Monday through

Thursday, 8:00 a.m. – 6:00 p.m., and Friday, 8:00 a.m. –

5:00 p.m. ET.
All unused pin locations must be populated by the

appropriate wire plug.
Figure 3 – Pin Assignments

PIN
DESIGNATION
PIN
DESIGNATION
DESIGNATION
1
Ignition Power
7
Sensor Signal, Front Axle Left

12 3 4

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